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The success of a product in the market is largely defined by the quality of design decisions made during the early stages of development. The product design requires designers to balance multiple objectives such as functionality, cost, and user satisfaction, while addressing the challenges posed by increasing product variants and customization demands. To tackle these challenges, one approach is to structure a comprehensive model that incorporates design for assembly (DFA) guidelines during the formulation of product architecture in the conceptual phase of development. While numerous strategies have been proposed in the literature, information is often scattered, making it difficult for readers to gain a comprehensive understanding of the topic. This paper systematically reviews the role and impact of DFA in product development, consolidating and presenting the information coherently. The review provides an overview of the methods developed, along with their potential benefits and limitations. A common framework is identified that defines the structure of the models, helping designers integrate assembly consideration into their design processes, thus reducing assembly time, cost, and complexity. The framework describes the operational setting, including the domain and context in which models operate, and offers a classification of possible methods and desired outputs. Additionally, the review identifies the industry in which case studies have been most frequently presented, and the software used to facilitate the process. By connecting with such a framework, future models can be created following a structured approach, and existing models can be classified and upgraded accordingly.

Improving resource efficiency by reducing waste and process inefficiencies across the building life cycle is essential for advancing sustainability in the built environment. Circular and industrialized construction offer complementary strategies to meet this challenge. While Design for Manufacturing and Assembly (DfMA) enhances constructability, standardization, and productivity in early project phases, Design for Disassembly (DfD) facilitates material recovery and adaptability at end-of-life. Despite their synergies, their integrated application remains underexplored. This study proposes a unified framework—Design for Manufacturing, Assembly, and Disassembly (DfMAD)—to align value creation and value retention strategies across the life cycle. A systematic literature review of 102 articles, following PRISMA guidelines, combined bibliometric and thematic analysis to identify key principles, benefits, barriers, and enablers of DfMA and DfD. Cross-mapping these findings revealed conceptual overlaps and distinctions and informed the synthesis of core DfMAD attributes. The resulting framework offers a life cycle-oriented approach that supports product-based delivery, traceability, and circular design strategies. By promoting shared logic across disciplines and project phases, DfMAD provides a foundation for operationalizing circularity in industrialized construction, contributing both theoretical and practical guidance for advancing resource-efficient, adaptable, and disassemblable building systems.

The design for manufacturing and assembly (DFMA) is a family of methods belonging to the design for X (DfX) category which goal is to optimize the manufacturing and assembly phase of products. DFMA methods have been developed at the beginning of the 1980s and widely used in both academia and industries since then. However, to the best of the authors’ knowledge, no systematic literature reviews or mapping has been proposed yet in the field of mechanical design. The goal of this paper is to provide a systematic review of DFMA methods applied to mechanical and electro-mechanical products with the aim to collect, analyse, and summarize the knowledge acquired until today and identify future research areas. The paper provides an overview of the DFMA topic in the last four decades (i.e., from 1980 to 2021) emphasizing operational perspectives such as the design phase in which methods are used, the type of products analysed, the adoption of quantitative or qualitative metrics, the tool adopted for the assessment, and the technologies involved. As a result, the paper addresses several aspects associated with the DFMA and different outcomes retrieved by the literature review have been highlighted. The first one concerns the fact that most of the DFMA methods have been used to analyse simple products made of few components (i.e., easy to manage with a short lead-time). Another important result is the lack of valuable DFMA methods applicable at early design phases (i.e., conceptual design) when information is not detailed and presents more qualitative than quantitative data. Both results lead to the evidence that the definition of a general DFMA method and metric adaptable for every type of product and/or design phase is a challenging goal that presents several issues. Finally, a bibliographic map was developed as a suitable tool to visualize results and identify future research trends on this topic. From the bibliometric analysis, it has been shown that the overall interest in DFMA methodologies decreased in the last decade.

Design for manufacture and assembly (DfMA) in the architectural, engineering, and construction (AEC) industry is attracting the attention of designers, practitioners, and construction project stakeholders. Digital fabrication (Dfab) and design for additive manufacturing (DfAM) practices are found in current need of further research and development. The DfMA’s conceptual function is to maximize the process efficiency of Dfab and AM building projects. This work reviewed 171 relevant research articles over the past few decades. The concepts and the fundamentals of DfMA in building and construction were explored. In addition, DfMA procedures for Dfab, DfAM, and AM assembly processes were discussed. Lastly, the current machine learning research on DfMA in construction was also highlighted. As Dfab and DFAM are innovated, practical DFMA techniques begin to develop to a great extent. Large research gaps in the DfMA for Dfab and DfAM can be filled in terms of integrating them with product structural performance, management, studied cases, building information modeling (BIM), and machine learning to increase operational efficiency and sustainable practices.

Based on problems with the Small Medium Enterprise (SME) of welding machine services. The Manual Metal Arch welding machine produced has a complex design, which causes high production prices and makes it uncompetitive in the market. Based on this issue, we need to analyze, redesign, and estimate assembly costs using the Design for Manufacture and Assembly (DFMA) approach, which will increase quality and reduce assembly costs. This research produces a new design using Acrylonitrile Butadiene Styrene (ABS) material. ABS has a better dielectric constant than sheet metal carbon steel, it can increase user safety. The use of ABS can reduce 54.39% of the number of components from 57 to 26 parts and reduce 36.16% of the total weight from 4013 to 2562 g. It is easier for user mobility. In addition, the use of DFMA methods can reduce 53.61% assembly time from 477.71 to 221.61 seconds, reduce 0.0999 $ assembly cost from 0.1863 to 0.0864 $/pcs, and increase assembly efficiency from 8.79 to 18.95%.

Rapid urbanisation and population growth call for more Industrialised Construction (IC) as a swifter, safer, higher-quality and affordable means of delivering housing and infrastructure. Meanwhile, rising global temperatures and extreme weather patterns call for immediate action to combat environmental degradation. The Building Construction Industry (BCI) is a leading contributor to global resource extraction and waste generation, posing a significant threat to our environment and planet. Design for Circular Manufacturing and Assembly (DfCMA) is an overarching design framework that synergises circularity (Design for Circularity (DfC)) and modularity (Design for Manufacturing and Assembly (DfMA)) by enhancing their shared values. This study explores the functional apparatus of DfCMA by identifying 21 DfMA constructs and 20 DfC constructs in the BCI through a rigorous literature review, first analysed descriptively, followed by Exploratory Factor Analysis (EFA) and Fuzzy Synthetic Evaluation (FSE) of the initial findings from a suitably focused questionnaire survey. The study findings confirm the significance of applying the 41 constructs above in advancing the concept of DfCMA in the BCI. This study thus adds value to research and practice, exploring the underlying mechanism of this novel DfCMA concept, which synergises two imperatives, promoting a Circular Economy (CE) and DfMA principles and practices in IC.

Product packaging has a huge impact on the efficiency of supply chain activities. In this research, the concept of Design for Assembly (DFA), proved in earlier studies to be effective at improving product manufacturing operations, is applied to the packaging system. We formulate the packaging system as a mathematical model for three different objectives. With respect to the continual rise in attention paid to sustainability, this research adds sustainability as one of the primary objectives. A case study demonstrates that the proposed model can achieve desired results and reveals a level of consistency among the three objectives. In addition to the application of DFA concepts to a packaging system, the contributions of this research lie in the development of a mathematical model (using integer programming and goal programming) for calculating the cost, handling time, and sustainability of the objectives in line with the design needs of the multi-level packaging size from the perspective of a supply chain to provide a range of solutions offering increased options for firms.

This paper discusses additive manufacturing (AM) and topology optimization (TO) and their relationship with industrial revolution 4.0. An overview of different AM techniques is given, along with the importance of design for manufacturing and assembly in progressing AM. The potential of AM to build complicated geometries with great precision has attracted a lot of interest in recent years. TO, one of the major enabling technologies in AM, has been essential in building compliant systems with improved performance across numerous industries. The development of hybrid mechanisms that integrate both compliant and stiff pieces because of improvements in “TO” algorithms has improved their usefulness and efficiency. Augmented realty and digital twins (DTs) have been used with “TO” to improve product design visualization and collaboration. Synergies between IN 4.0, TO, and AM have been discussed along with their cross-domain relevance. Machine learning involvement for more robust integration of IN 4.0 with TO and AM have also been discussed. The development of the Digital Triad, which combines DTs, digital threads, and digital trust to enable effective and secure data sharing and cooperation, is the result of the convergence of internet-of-things, cloud computing, and big data analytics. However, concerns about data privacy and cybersecurity still need to be resolved. The use of machine learning algorithms for cyberattack detection and mitigation as well as secure block chain-based frameworks for managing intellectual property rights are just a few of the frameworks and tactics that researchers have suggested to lower cybersecurity risks in AM systems. The establishment of new standards and guidelines for the cybersecurity of AM systems is anticipated to result from ongoing research in this area.

DFA (Design for assembly) is an important part of the contents included in some of the manufacturing courses taught at Jaume I University. DFA is a tool to analyse and improve product design from an assembly point of view. Although DFA contents had been covered using different teaching activities (theoretical, problem and laboratory sessions), the results in students’ assessment revealed that the expected learning outcomes were not being achieved. In particular, results were especially unsatisfactory in the practical application of DFA. Students misunderstood concepts such as “handling” and “insertion” operations, and failed at identifying assembly problems related to thickness or alignment among others. A learning by doing approach has been proved to improve students’ learning and engagement, as they take an active role and have the opportunity of doing things themselves. In a previous work, a specific modular and reconfigurable kit to improve DFA learning by experimentation was designed. Based on this work, this paper presents the analysis of the results obtained in two different courses where the modular kit has been used by students in a new seminar session.

The construction industry, despite its anticipated significant growth, has struggled with low productivity over the past two decades. Design for manufacturing and assembly (DfMA), a methodology with a history of success in other industries, presents a promising solution to enhancing efficiency in construction. This article reviews the current state of DfMA in the construction industry, identifies the most recent research themes in the field of DfMA, and provides recommendations for future DfMA research based on the existing research gaps. The paper employs a mixed-method approach, combining quantitative bibliometric analysis and qualitative thematic analysis. Using Scopus as the literature database, the study identified 43 relevant articles published between 2013 and 2023. The bibliometric analysis reveals a growing interest in DfMA research, with an upward trend in publications over the years. The thematic analysis categorizes DfMA research topics into six main themes: Innovation and Technology Trends, Sustainability and Environmental Impact, Regulatory and Policy Considerations, Collaborative Approach, Applications, Benefits, and Challenges, and Project Lifecycle. Each theme is explored in-depth, providing insights into the transformative impact of technology, environmental considerations in DfMA, regulatory challenges, collaborative strategies, varied applications, and the project lifecycle phases influenced by DfMA. The article concludes by presenting identified research gaps and offering recommendations for future DfMA research. It emphasizes the need for a holistic approach, continued collaboration, and a focus on unexplored aspects of regulatory frameworks and the entire project lifecycle. This study sets a new benchmark in DfMA research by employing a novel mixed-method approach and providing unprecedented insights into the multifaceted role of DfMA in advancing construction industry practices. It serves as a valuable resource for researchers, practitioners, and stakeholders in the construction industry by offering a comprehensive understanding of DfMA’s current state and guiding future research endeavors.